CONTENTS Product Features and Specifications...1 Installation Requirement... 3 Steps of Installation.. 5 Exploded View...18 Test Run...21 Operation Instruction...22 Maintenance... 23 Trouble Shooting... 24 Parts List... 25 1
I. PRODUCT FEATURES AND SPECIFICATIONS FLOORPLATE CHAIN-DRIVE TWO POST LIFT Model BP-10000 (See Fig. 1) Compact design Dual hydraulic cylinders, designed and made on ANSI standards, utilizing NOK oil seals in the cylinders Self- lubricating UHMW Polyethylene sliders and bronze bushings Single-point safety release and dual safety design Super Symmetric arms design with 3-stages front arms and 2-stages rear arms. Stackable rubber pad with 1.5, 2.5 and 5 extension adaptors Fig. 1 MODEL BP-10000 SPECIFICATIONS Model Style Lifting Capacity Lifting Time Lifting Height Overall Height Overall Width Width Between Columns Minimum Pad Height Gross Weight Motor BP-10000 Floor plate Chain-drive 4.5T 10,000lbs 62S 1965-2194mm 77 3/8 86 3/8 2841mm 111 7/8 3534mm 139 1/8 2850mm 112 1/4 115mm 4 1/2 745Kg 1640lbs 3.0 HP 1
Arm Swing View For Model BP-10000 Fig. 2 2
II. INSTALLATION REQUIREMENT A. TOOLS REQUIRED Rotary Hammer Drill (3/4 ) Carpenter s Chalk Hammer Screw Sets Level Bar Tape Measure Crescent Wrench (12") Pliers Ratchet With Socket (28 mm ) Allen Head Wrench (6 mm ) Wrench set (mm) Vise Grips (10 #, 13 #, 14 #, 15 #, 17 #, 19 #, 24 #, 27 # ) Fig. 3 3
B. SPECIFICATIONS OF CONCRETE (See Fig. 4). Specifications of concrete must be adhered to the specification as following. Failure to do so may result in lift and or vehicle falling. 1. Concrete must have 4 inches minimum and must be totally cured before lift installation. 2. Concrete must be in good condition and must have a test strength 3,000psi minimum. 3. Floors must be level with no cracks or holes. 71 Concrete strength 3000psi 4 4 Fig. 4 C. POWER SUPPLY 220 volt single phase motor on a 30 amp breaker with minimum of 10 gauge wire. Operating voltage range is 208v-230v. 4
III. Location of installation A. Location of Installation Check and ensure the installation location (concrete, layout, space size etc.) is suitable for lift installation. B. Use a carpenter s chalk line to establish installation layout of base plate (See Fig. 5). Click line 139-1/8 Fig. 5 Model BP-10000 C. Check the parts before assembly. 1. Packaged lift, hydraulic power unit and parts box (See Fig. 6). 2. Move the lift with fork lift or hoist, open the outer packing and check the parts with the shipment list (See Fig. 7). Fig.6 Fig.7 Shipment Parts list Floor cover Metal Serial No. Parts box 5
3. Loosen the bolts on the upper package stand, remove the upper column then remove the package stand. 4. Set aside the parts and check the parts according to the shipment parts list (See Fig. 8). 81 Fig. 8 5. Open the carton of parts and check the parts according to parts box list (See Fig. 9). Fig. 9 6. Check the parts in the parts bag according to parts bag list (See Fig. 10). Fig. 10 6
D. Position power side column Lay down two columns on the installation site parallel. Position the power side column according to the actual installation site and install top plate and top connecting plate assembly. Usually, it is suggested to install power side column on the front-right side from which vehicles are driven into the lift (See Fig. 11). Power side column Offside column Car-in direction Install top connecting plate with M8*20 hex bolt, nut and lock washer Fig. 11 E. Connecting the cables 1.Push the carriages higher than chain pulley (See Fig. 12). B, Push the carriages higher than chain pulley, cable passes through the top of the carriages and passes through the hole on the bottom steel plate of the carriages C, Pull out cable A, Cable pass in the carriage Fig. 12 7
2.Push the carriages to the bottom of the columns (See Fig. 13). Fig. 13 F. Position columns (See Fig. 14) Check the columns plumb with a level bar, and adjust with the shims if the columns are not level. 112-1/4 Check the columns plumb with level bar 72 139-1/8 Fig. 14 8
G. Fix anchor bolts Washer Lock washer Nut 1. Prepare anchor bolts (See Fig. 15). Fig. 15 2. Use a rotary hammer drill and drill all the anchor holes and install the anchor bolts. Then tighten the anchor bolts. If the top of the anchor exceeds 2-1/4 above the floor grade, you DO NOT have enough embedment (See Fig. 16). Torque anchors to 150lbs. H. Lift the carriages up by hand and make so they lock at the same level (See Fig. 17). Fig. 16 Fig. 17 9
I. Install cables (See Fig. 18) The fitting of cable passes through the hole on the carriages and is held with two cable nuts. Fig. 18 10
J. Assembly oil hose assembly. (See Fig. 19). Fig. 19 11
K. Install hydraulic power unit and oil hose assembly. (See Fig. 20). Tighten all the hydraulic fittings and fill the reservoir with approximately 3 gallons of hydraulic oil. Note: In consideration of Power Unit s durability and keeping the equipment running in good condition, please use Hydraulic Oil AW32 Locking the nut using 19 mm socket or wrench Fig. 20 12
L. Install safety the device and safety cable (See Fig. 21). NOTE: 1. Assemble safety cable from offside safety assembly first. 2. Pay attention to the connecting direction on the safety cable. View A Safety cable Connecting direction View B Fig. 21 13
M. Assemble floor cover and protective rubber door guards (See Fig. 22). Floor Cover Protective rubber guards Fig.22 N. Install lifting arms and adjust the arm locks 1. Install the lifting arms (See Fig. 23) Fig.23 2. Lower the carriages down to the lowest position, then use the 17 mm wrench to loosen the nut (See Fig. 24) Loosen the nut Fig. 24 14
3. Adjust the arm lock as arrow direction (See Fig. 25) Arm lock Fig. 25 4. Adjust the moon gear and arm lock so it meshes, tighten the bolts on the arm lock (See Fig. 26) Moon gear and arm lock engaged Tighten the nuts Fig. 26 15
O. Install the Electrical System Connect the power source on the data plate of Power Unit. Operating voltage range 208v-230v. Remove the short Pig Tail wire connected to the AC contactor terminals. This wire was used to test the motor after production. ATLAS Single phase motor Please Note: This motor is powered by Alternating Current and the terminals on the AC contactor are not wire color specific. There are no positive or negative terminals. 1. Connect the two power supply (incoming) wires (black & white) to terminals on the AC contactor marked L2 & L3. 2. Connect the two motor wires to terminals on the AC contactor marked T2, T3. These wires are already connected from the factory. 3. Connect the short wire A2 to L3 on the AC contactor. This wire is already connected from the factory. AC CONTACTOR 16
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IV.EXPLODED VIEW Model BP-10000 Fig. 27 18
Cylinders Fig. 28 19
Illustration of hydraulic valve for ATLAS hydraulic power unit ATLAS manual power unit, 220V/60HZ, Single phase (See Fig.29) Running capacitor Start capacitor Protective ring Relief valve Oil return port Oil Outlet Release valve Check valve Handle for Release valve Throttle valve Fig. 29 ATLAS MANUAL POWER UNIT 220V/60HZ/1Phase Fig. 30 20
V. TEST RUN 1. Adjust the equalizing cables (See Fig. 31) Use wrench to hold the cable fitting, meanwhile Use a ratchet to tighten the cable nut. Make sure the cables have the same tension First Safety so the two carriages lift at the same time. lock Replace the covers on the carriages. If the carriages do not lift at the same time, tighten the cable nut on the lower of the two carriages. Cable nut Fig. 31 2. Adjust safety cable Lift the carriages and lock at the same height, pull the safety cable and then release a little, and then tighten the cable nuts. Make sure the safety locks click at the same time. 3. Adjust the lower speed (Only for ATLAS power unit) (See Figure 32) You can adjust the lowering speed of the lift if necessary: Loosen the locking nut on the throttle valve, and then turn the throttle valve clockwise to decrease the lowering speed, or counterclockwise to increase the lowering speed. Do not forget to tighten the locking nut after the lower speed adjustment has been completed. Throttle Valve Fixing Nut Clockwise to decrease the lowering speed Counterclockwise to increase the lowering speed Fig. 32 21
4. Test with load After finishing the above adjustments, test run the lift with load. Run the lift in low position for several times first. Make sure the lift can raise and lower at the same time so the Safety Device can lock and release. Test run the lift to the top completely. The above adjustments may need to be repeated. NOTE: If the lift vibrates on the way up with a load, lubricate all pulley shafts and wear blocks. If the lift vibrates on the way down, the cylinders need to run all of the way up and down to evacuate any residual air. Figure 33 Hydraulic System VI. OPERATION INSTRUCTIONS Please read the safety tips carefully before operating the lift To lift vehicle 1. Keep clean of site near the lift; 2. Position lift arms to the lowest position; 3. To shortest lift arms; 4. Open lift arms; 5. Position vehicle between columns; 6. Move arms to the vehicle s lifting point; Note: The four lift arms must at the same time contact the vehicle s lifting point where manufacturers recommended 22
7. Press the UP button until the lift pads contact underside of vehicle totally. Recheck to make sure vehicle is secure; 8. Continue to raise the lift slowly to the desired working height, ensuring the balance of vehicle; 9. Push lowering handle to lower lift onto the nearest safety. The vehicle is ready to repair. To lower vehicle 1. Be sure clear of around and under the lift, only leaving operator in lift area; 2. Press the button of UP to raise the vehicle slightly, and then release the safety device, lower vehicle by pushing lowering handle. 3. Open the arms and position them to the shortest length; 4. Drive away the vehicle. 5. Turn off the power. VII. MAINTENANCE SCHEDULE Monthly: 1. Re-torque the anchor bolts to150 lbs.; 2. Check all connectors, bolts and pins to insure proper mounting; 3. Lubricate cable with lubricant; 4. Make a visual inspection of all hydraulic hoses/lines for possible wear or leakage; 5. Check Safety device and make sure it is in good condition; 6. Lubricate all Rollers and Pins with 90wt. Gear oil or equivalent; Note: All anchor bolts should take full torque. If any of the bolts do not function for any reason, DO NOT use the lift until the bolt has been replaced. Every six months: 1. Make a visual inspection of all moving parts for possible wear, interference or damage. 2. Check and adjust as necessary, equalizer tension on the cables to insure level lifting. 3. Check columns for plumb. 4. Check Rubber Pads and replace as necessary. 5. Check Safety device and make sure it is in good condition. 23
VIII.TROUBLE SHOOTING TROUBLE CAUSE REMEDY 1. Button does not work 2. Wiring connections are not in good 1. Replace button 2.Repair all wiring connections Motor does not run condition 3. Motor burned out 4. AC contactor in damage 3. Repair or replace motor 4. Replace or replace Motor runs but the lift is not raised 1. Motor runs in reverse rotation 2. Gear pump out of operation 3. Release valve in damage 4. Relief valve or check valve in damage 5. Low oil level 1.Reverse two power wire 2.Repair or replace 3. Repair or replace 4.Repair or replace 5.Fill tank Lift does not stay up 1. Release valve out of work 2. Relief valve or check Valve leakage 3. Cylinder or fttings leaks Repair or replace Lift raises slowly 1. Oil line is jammed 2. Motor running on low voltage 3. Oil mixed with air 4. Gear Pump leaks 5. Overload lifting 1. Clean the oil line 2. Check electrical system 3. Fill tank 4. Replace pump 5. Check load Lift can not lower 1. Safety device are locking. 2. Release valve in damage 3. Safety cable broken 4. Oil system is jammed 1. Release the safeties 2. Repair or replace 3. Replace 4. Clean the oil system 24
IX. PARTS LIST FOR MODEL BP-10000 Item Part# Description Qty. Note 1 203072 Power side column 1 2 209011 Plastic Pulley 1 3 209010 Snap Ring 2 4 209008 Safety Cover 2 5 209009 Cup Head Bolt 4 6 206006 Washer 2 7 206023A Hex Nut 2 201 209002 Manual Power Unit 1 9 206002 Safety Pin 2 10 209007 Safety Spring 2 11 203002 Power side Safety Lock 1 12 209012 Hair Pin 8 13 203015 Safety Block (Main) 1 14 209003 Hex Bolt 4 15 209004 Rubber Ring 4 16 209005 Self locking nut 12 17 203076 Floor Cover 1 18 217114A Rubber Pad Assy. 4 18A 420138 Socket bolt 4 18B 209134 Rubber Pad 4 18C 680030B Rubber Pad Frame 4 19 209039 Lock Washer 14 20 209038 Hex Bolt 6 21 209057 Small Pulley 4 22 209056 Self locking nut 2 23 201010A Chain Connector 4 24 203005 Chain 2 25 203078 Hydraulic Cylinder 2 26 203040 Pin For Chain Pulley 2 27 203004A Bronze bush for Chain Pulley 4 28 203004 Chain pulley 2 29 201005 Split Pin 2 30 201004 Chain Pulley Assy. 2 31 203074 Powerside Carriage 1 32 206044 Slider 16 33 209016 Carriage Plastic Cover 2 34 206045 Protective Rubber 2 35 206046 Self-tapping Screw 4 36 209020 Plastic Ball 4 37 209021 Hex Nut 8 38 209022 Washer 10 25
Item Part# Description Qty. Note 39 209023A Arm lock 4 40 201041 Limit Ring 4 41 209024 Arm Lock Bar 4 42 209025 Hair Pin 4 43 209026 Spring 4 44 209027 Protective Rubber Set 4 45 209029A Lifting Arm - Front Right 1 45A 209137 Outer Arm - Front Right 1 45B 206088 Middle Arm - Front Right 1 45C 206089A Inner Arm - Front Right 1 46 209036A Lifting Arm - Front Left 1 46A 209138 Outer Arm - Front Left 1 46B 206093 Middle Arm - Front Left 1 46C 206089A Inner Arm - Front Left 1 47 209037A Lifting Arm - Rear Left 1 47A 209139 Outer Arm - Rear Left 1 47B 209140A Inner Arm - Rear Left 1 48 203075 Offside Carriage 1 49 209028A Lifting Arm - Rear Right 1 49A 209135 Outer Arm - Rear Right 1 49B 209136B Inner Arm - Rear Right 1 50 209035 Moon Gear 4 51 209033 Washer 20 52 209034 Lock Washer 12 53 209032 Socket Bolt 12 54 209030 Arm Pin 4 55 203009 Connecting Bar 2 56 209043 Hex Bolt 8 57 209046 Hex Bolt 4 58 203077 Top plate 2 59 209045 Big Pulley 2 60 209057A Bronze Bush For Pulley 6 61 203073 Offside column 1 62 209049 Plastic Pulley 3 63 203012 Offside Safety Lock 1 64 203013 Coupling 2 65 203014 Safety Block (Secondly ) 1 66 203018 Socket Bolt 4 67 203016 Snap Ring 4 68 209051B Stackable Adapter (1.5 ) 4 69 209052B Stackable Adapter (2.5 ) 4 70 209053B Stackable Adapter (5 ) 4 71 209059 Anchor bolt 12 26
Item Part# Description Qty. Note 72 620065 Shim 10 73 209069 Cable 2 74 209066 Cable Nut 4 75 201022 T-Fitting 1 76 203070 Oil Hose 1 77 201020 90 0 Fitting 1 78 201021 Oil Hose 1 79 209060 90 0 Fitting for Power Unit 1 80 203071 Safety Cable 1 81 203502 Parts Box 1 Parts For Hydraulic Cylinder 25-1 201027 Piston Rod 2 25-2 203079 Piston 2 25-3 206069 O-Ring 2 25-4 203080 Support Ring 2 25-5 410087 Y-Ring 2 25-6 203082 O-Ring 2 25-7 206071 Hex Nut 2 25-8 201037 Adjustment Tube 2 25-9 209078 Dust Ring 2 25-10 201032 O-Ring 2 25-11 203083 Head Cap 2 25-12 201034 Bleeding Plug 2 25-13 203084 O-Ring 2 25-14 203085 Bore Weldment 2 27
Parts For ATLAS Manual Power Unit 220V/60HZ/1Phase Item Part# Description Qty. Note 201A-1 209082A Motor 1 201A-2 209109 Protective Ring 1 201A-3 209112 AC contactor 1 201A-4 209083A Motor Connecting Shaft 1 201A-5 209084A Valve Body 1 201A-6 209085A Relief Valve 1 201A-7 209113 Throttle valve 1 201A-8 209086A Lock Washer 4 201A-9 209087A Socket Bolt 4 201A-10 209088A Inlet Pipe 1 201A-11 209089A O-Ring 1 201A-12 209090A Filter 1 201A-13 209091A Socket bolt 4 201A-14 209092A Reservoir (10 liter) 1 201A-15 209093A Cup Head Bolt with washer 4 201A-16 209094A Cover of Capacitor 2 201A-17 209095A Start Capacitor 1 201A-17A 209095B Run Capacitor 1 201A-18 209096A Rubber Gasket 2 201A-19 209097A Cup Head Bolt with washer 2 201A-20 209098A Cover of Motor Terminal Box 1 201A-21 209099A Push Button 1 201A-22 209110A Oil Return Port 1 201A-23 209100A Oil Outlet 1 201A-24 209105A Check Valve 1 201A-25 209101A Release Valve 1 201A-26 209102A Handle For Release Valve 1 201A-27 209103A Washer 1 201A-28 209104A Hex Nut 1 201A-29 209106A Gear Pump 1 201A-30 209107A Oil Return Pipe 1 201A-31 209108A Filler Cap 1 28